Pluggable module for a communication system

Abstract

A pluggable module includes a pluggable body extending lengthwise between a mating end and a cable end. The pluggable body has a first end and an opposite second end with sides extending therebetween along a length of the pluggable body. The first end, second end and sides define a cavity. An internal circuit board is held in the cavity. The internal circuit board is provided at an end of a cable communicatively coupled to the internal circuit board. The pluggable body is configured to be plugged into a receptacle assembly such that the internal circuit board is communicatively coupled to a communication connector of the receptacle assembly. The pluggable body is defined by a first shell including the first end and the sides and may be formed by extrusion and may have increased thermal conductivity and a second shell including the second end.

What is claimed is: 
     
       1. A pluggable module comprising:
 a pluggable body extending lengthwise between a mating end and a cable end, the pluggable body having a first end and an opposite second end with sides extending therebetween along a length of the pluggable body, the first end, second end and sides defining a cavity; and 
 an internal circuit board held in the cavity, the internal circuit board being provided at an end of a cable communicatively coupled to the internal circuit board, wherein the pluggable body is configured to be plugged into a receptacle assembly such that the internal circuit board is communicatively coupled to a communication connector of the receptacle assembly; 
 wherein the pluggable body is defined by a first shell and a second shell, the first shell comprising the first end and the sides, the second shell comprising the second end, the first shell including an extruded body having a fixed cross-sectional profile from the mating end to the cable end. 
 
     
     
       2. The pluggable module of  claim 1 , wherein the second shell is nested in the first shell such that the second end extends between the sides. 
     
     
       3. The pluggable module of  claim 1 , wherein the second end caps the first shell to close a space between the sides. 
     
     
       4. The pluggable module of  claim 1 , wherein the sides of the first shell comprise at least 90% of the sides of the pluggable body. 
     
     
       5. The pluggable module of  claim 1 , wherein the cavity has a center plane centered between the first and second ends, the sides of the first shell extending beyond the center plane such that the first shell is on both sides of the center plane. 
     
     
       6. The pluggable module of  claim 5 , wherein the second shell is completely positioned on one side of the center plane. 
     
     
       7. The pluggable module of  claim 1 , wherein the second shell has a non-uniform cross-section from the mating end to the cable end. 
     
     
       8. The pluggable module of  claim 1 , wherein the first shell defines an upper shell and the second shell defines a lower shell, the internal circuit board captured between the upper shell and the lower shell, the upper shell receiving the internal circuit board such that the upper shell is positioned both above and below the internal circuit board. 
     
     
       9. The pluggable module of  claim 1 , wherein the first shell and the second shell define a perimeter around the cavity, the first shell defining at least two thirds of the perimeter. 
     
     
       10. The pluggable module of  claim 1 , wherein the first shell is manufactured from a first material and the second shell is manufactured from a second material different than the first material, the first material having a higher thermal conductivity than the second material, the first shell being in thermal communication with the internal circuit board to transfer heat from the internal circuit board. 
     
     
       11. A pluggable module comprising:
 a pluggable body defined by an extruded shell and a die cast shell coupled to the extruded shell, the extruded shell comprising a first end extending lengthwise between a mating end and a cable end, the die cast shell comprising a second end extending lengthwise between the mating end and the cable end, at least one of the extruded shell and the die cast shell comprising sides between the first and second ends, the first end, the second end and the sides defining a cavity; and 
 an internal circuit board held in the cavity, the internal circuit board being provided at an end of a cable communicatively coupled to the internal circuit board, wherein the pluggable body is configured to be plugged into a receptacle assembly such that the internal circuit board is communicatively coupled to a communication connector of the receptacle assembly. 
 
     
     
       12. The pluggable module of  claim 11 , wherein the die cast shell is nested in the extruded shell such that the second end extends between the sides of the extruded shell. 
     
     
       13. The pluggable module of  claim 11 , wherein the second end caps the extruded shell to close a space between the sides. 
     
     
       14. The pluggable module of  claim 11 , wherein the sides of the extruded shell comprise at least 90% of the sides of the pluggable body. 
     
     
       15. The pluggable module of  claim 11 , wherein the extruded shell includes an extruded body having a substantially uniform cross-section from the mating end to the cable end, and wherein the die cast shell includes a die cast body having a non-uniform cross section from the mating end to the cable end. 
     
     
       16. The pluggable module of  claim 11 , wherein the extruded shell is manufactured from a first material and the die cast shell is manufactured from a second material different than the first material, the first material having a higher thermal conductivity than the second material, the extruded shell being in thermal communication with the internal circuit board to transfer heat from the internal circuit board. 
     
     
       17. A pluggable module comprising:
 a pluggable body defined by a first shell and a second shell, the first shell comprising a first end extending lengthwise between a mating end and a cable end, the second shell comprising a second end extending lengthwise between the mating end and the cable end, at least one of the first shell and the second shell comprising sides between the first and second ends, the first end, the second end and the sides defining a cavity; and 
 an internal circuit board held in the cavity, the internal circuit board being provided at an end of a cable communicatively coupled to the internal circuit board, wherein the pluggable body is configured to be plugged into a receptacle assembly such that the internal circuit board is communicatively coupled to a communication connector of the receptacle assembly; 
 wherein the first shell includes an extruded body having a substantially uniform cross-section along the length between the mating end and the cable end, the second shell has a non-uniform cross-section between the mating end and the cable end, the non-uniform cross-section being defined by at least one pocket receiving the electrical component of the internal circuit board. 
 
     
     
       18. The pluggable module of  claim 17 , wherein the second shell includes a die cast body having the non-uniform cross-section. 
     
     
       19. The pluggable module of  claim 17 , wherein the first shell is manufactured from a first material and the second shell is manufactured from a second material different than the first material, the first material having a higher thermal conductivity than the second material, the first shell being in thermal communication with the internal circuit board to transfer heat from the internal circuit board.